Boost Converter Current Sensor Nesting
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Solution Overview
Problem
The existing layout of boost converters in vehicles, which arrays the reactor, semiconductor module, and current sensor in a horizontal direction to reduce height, results in increased horizontal dimensions, making it difficult to mount in limited spaces like the front room of a vehicle, where stricter height limitations apply.
Innovation Solution
A boost converter configuration where the semiconductor modules are stacked and held by a frame-like holder portion, with a current sensor integrated within the first bus bar, positioned inside the range defined by the ends of the holder portion, preventing horizontal dimension increase compared to a layout with the current sensor outside this range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the reactor, semiconductor module and current sensor are arrayed in a horizontal direction to reduce the total height of the boost converter, then the height dimension is improved, but the horizontal dimension increases making it difficult to mount in the front room of the vehicle
Solution Approach 1:
The current sensor is nested within the holder portion structure, specifically positioned inside the range defined by the respective ends of the holder portion in the array direction. This nesting arrangement allows the current sensor to be integrated into the existing structural footprint rather than adding external horizontal dimension, resolving the contradiction between reduced height and controlled horizontal size.
Solution Approach 2:
The patent transitions from a purely horizontal arraying of components to a three-dimensional arrangement where the current sensor is positioned vertically within the holder portion's footprint. By utilizing the vertical space within the existing horizontal boundary (inside the range defined by holder portion ends), the design achieves compact horizontal dimensions while maintaining the benefits of horizontal component arraying.
2Ease of operation
If the current sensor is entirely placed outside of the range defined by the holder portion ends in the array direction, then the current sensor has sufficient space for operation, but the horizontal dimension of the boost converter increases
Solution Approach 1:
The current sensor is merged with the holder portion structure by positioning it inside the range defined by the holder portion ends. This merging combines the functional space requirements of the current sensor with the structural footprint of the holder portion, eliminating the need for additional horizontal space while ensuring the current sensor has adequate operational space within the integrated structure.
3Volume of moving object
If the semiconductor modules are stacked and pressurized inside the holder portion frame, then the vertical space utilization is improved, but the structural complexity increases
Solution Approach 1:
The holder portion is designed with multi-functionality, serving both as the structural frame that holds the semiconductor modules and as the boundary definition for the current sensor placement. This universal structure performs multiple functions (support, containment, and spatial definition) without requiring separate dedicated components, thereby achieving efficient space utilization while controlling structural complexity.
Data Source
AI summary
There is provided a boost converter. The boost converter comprises a reactor electrically connected with a power source; a semiconductor module configured to include a plate-like member and a terminal protruded from the plate-like member; a holder portion provided as a frame-like member, arranged to be adjacent to the reactor along either a longitudinal direction of a vehicle or a vehicle width direction, and configured to hold a plurality of the semiconductor modules inside of a frame of the holder portion such that the plurality of semiconductor modules are stacked and pressurized; and a first bus bar arranged to electrically connect the reactor with the terminal and provided with a current sensor that is configured to detect an electric current flowing from the reactor to the semiconductor modules. At least part of the current sensor is provided in the first bus bar such as to be placed inside of a range that is defined by respective ends of the holder portion in an array direction in which the reactor and the holder portion are arranged to be adjacent to each other. This configuration prevents increase of the dimension of the boost converter either in the longitudinal direction of the vehicle or in the vehicle width direction.